Abstract
In the existing automobile manufacturing process, metal inert gas (MIG) and tungsten inert gas (TIG) welding are mainly used. These welding methods are fusion welding, and the heat input in the welding area is very high. Therefore, the deformation of the base material is large, and the residual stress in the vicinity of the welded area is high, resulting in the problem of reduced mechanical strength. In this study, friction stir welding (FSW) was applied to the welding process of the structure constituting the battery frame of a newly developing electric vehicle to compensate for this problem. The welded part is the fillet joint of the side frame and the bottom frame, and experiments and numerical analysis were performed on the welding deformation and residual stress of the full frame structure. A specially manufactured angle head was used for friction stir welding of the fillet joint of extruded type aluminum, not the existing solid type. The optimum process was derived through experiments, and the temperature of the welding center was derived through test correlation between the value of measured temperature and the finite element model. The final deformation result was verified by comparing it with the measured value using a dial indicator. It is expected that the proposed thermal elasto-plastic analysis method will reduce the testing period and the cost of the manufacturing process and increase productivity.
Highlights
Friction stir welding (FSW) is a solid-state welding method developed by the Welding Institute (TWI) in the UK in 1991 that uses frictional heat to join two workpieces at temperatures below the base material’s melting point
This study performed friction stir welding (FSW) by tilting the tool at an angle of 45 degrees for four fillet joints where the bottom frame and the side frame were in contact, as shown in the solid line and the dotted line frame structure and equipment were set as shown in Figure4 of
The frictional heat generated between the tool and the base material is the heat source of the welding center when performing FSW and this is a significant factor in determining the strength of welding center when performing FSW and this is a significant factor in determining the strength of the weld joint
Summary
FSW is performed by pressing a cylindrical tool with a spiral pin rotated at high speed on the joint between the two fixed base materials. These fusion welding cause excessive and laser welding are used for processes These fusiontechniques welding techniques cause welding excessive welding deformation and residual stress in addition to the phase change of the base material around the weld because the heat input is very high. The hollow cross-sectional structure ofof the side frame is is structure inin which the inside the base material not full solids. Itis is much more difficult perform fillet joint welding hollow cross-sectional. It much more difficult to perform fillet joint welding on hollow cross-sectional. It is much more difficult toto perform fillet joint welding onon hollow cross-sectional structures compared specimen units.
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